MSFC Skylab Airlock Module, Volume 1

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    ,,, TECHNICAL REPORT STANDARD T|TLE[ PAGE'1 NIEPONT NO. I z GOVERN.NT ACCESSION NO. J 3.' RECIPIIrNT'S CATALOG NO.! Iq_qA TMX-64810 ,,

    i. TITLE AkO SUITITLE i _ =[:_O_*T _,ATt"Apml I q7dMSFC Skylab A:rlock Module 16 P[_O_Mlm,OmGANIZATIONCOOZ

    _ V,,i. I [7. AUTHOIqIS) I 8, PERPONMING 0_GANIZATION Iq[p(_r II9. PERIrONMING OiqGANIZATION NAME AN0 ADDRESS tt_. Wt_K UNIT NO.

    George C. Marshall Space Flight CenterMarshall Space Fhght Center, AL 35812 I CONr,*X',OP.n'NrNO.

    |1. TYPE 0 Ir IPi[PON', _ PEAlOO COVERED12. $1i0NSOAING AGENCY NAkCl AND #.ODRI[SS FLn,,I Rel)ortNational k,-,ronautics and Space Admir, istratlon Technical MemorandumWashm_',on, b. C. 20546 ,4 S_ONSOM,._=t.CV0OC

    IS. SUPPLEMENTARY NOTES

    Lirlock/M ultiple D_ck,ng Adapter Project Office16, A! STIIACT

    This report presents the history and development of the Skylab Airlock Moduleand the Payload Shroud, NASA Contract No. NAS9-6555, from initial conceptthrough final design, related test programs, mission performance and lessonslearned.

    Althouqh so,c.e problems were encountered, the Alrlock Module performedsuccessfully throughout the three manned Skylab missions.

    NOTE: Volume I - Sections 1.0 through 2.95.Vo_um,, Ii - Sections 2.10 through 8.0.

    II 17[ KEY WOIlOS 18. DISTAIIIUTION STATEMENT

    Ur_lassified-unli mite(t

    j. CoolPr_ct Manager,Alrlock,/lVlultiple Docking AdapterJ

    U ncla s s : fled U ncla s st fled 629 NTIS_llrC Yore ! I i t"_Rrv Dec*m_, | | I ! ) "' Fo( ,hi, by National Technical Infornt,tton S, rvt,. Sprmlfleld. Virllnll III $1

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    AIRLOCK MODULE FINAL TECHNICAL REPORT MDC E0899 VOLUME I!

    TABLE OF CONTENTSVOLUME I

    SECTION I INTRODUCTION l-Il.l PURPOSE AND SCOPE l-I1.2 SU_C_ARY I-21.2.1 Airlock Features l-2l.?.2 Airlock Module Weight and Dimensions I-9lo2.3 FAS Weight and Dimensions I-91.2.4 DA Weight and Dimensions l-lO1.2.5 Payload Shroud (PS) l-lO1.2.6 Environmental/ThermalControl Systems (ECS/TCS) l-ll1.2.7 Electrical Power Syste_ (EPS) 1-121.2.8 Sequential System l- 21.2.9 InstrumentationSystem 1-12l 2.10 CommunicationsSystem 1-13l 2.1l Caution and Warning System (C&W) 1-14l 2.12 Crew Systems ]-15l 2.13 Trainers 1-16l 2.14 Experiments ]-16l 2.15 Ground Support Equipment (GSE) 1-17l 2.16 Roliability and Safety 1-17l 2.17 Testing 1-18l 2,18 Mission Operations Support 1-191.2.19 New Technology 1-201.2.20 Conclusions 1-21

    SECTION 2 SYSTEM DESIGN AND PERFORMANCE 2.l-I2.l GENERAL 2.l-l2.1.l Program Inception 2.1-I2.1.2 SSESM 2.l-I2.1.3 Wet Wcrkshop Evolution 2.1-32.1.4 Wet Workshop Configuration 2.1-62.1.5 Dry Workshop Configuration 2.1-62 2 STRUCIURES AND MECHANICAL SYSTEMS 2.2-I2.2.1 Design Requirements 2.2-I2.2.2 Systems Description 2.2-4

    ivPRBC.,EDING PAGE BLANK NOT FILMI'I'I'I_

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    AIRLOCK MODULE FINAL TECHNICAL REPORT MDCEOe. VOLUMTAL_LEOF CONTENTSVOLU_ I CONTINUED

    .'.2.3 by"ternVerltIcation 2.2-22J.2.4 Mission Res,Jls 2.2-302.2.') O,rtclusionsand RecGm,w_ndations 2.2-31) 3 _A'c PROPERTIES 2.3-12 3.l A1rlock Wei:sht,MonitoringPlan 2.3-1

    3.2 Actadl _le],iht Program 2.3-I3.1 Lajnch Weight 2.3-6

    ? 4 THERMAL CONTROL SYSTEM 2.4-I/ 4.1 Design Require_nts 2.4-I2 4.2 IntegrateOTl_ermalAnalysis 2.4-52.4.3 System Description 2.4-132 4." ;esting 2.4-60? 4.5 Mission Performance 2.4-982 4.6 Development Problems 2.4-122 4.7 Conclusionsand Recommendatlons 2.4-122 5 ENVIRONMENTALCONTROL SYSTEM 2.5-12 5.1 Design Requirements 2.5-12 5.2 System Description 2.5-9? 5.3 Testing 2.5-562 5.4 Mission Results 2.5-882 5.5 Development Problems 2.5-112 5.6 Conclusions and Recommeadat'ions 2.5-122 6 EVA/IVA SUIT SYSTEM 2.6-12 6.; Design RequiremePts 2.6-1

    r . ..... ipt.,,._ oy_t.v Descr ion 2.6-42.6.3 Testing 2.6-2_2.6.4 Mission Performance 2.6-46

    :' 2.6.5 Development Problems 2.6-52@ 2.6.6 Conclusions and Recor,_endations 2.6-54

    2.7 ELECTRICAL POWER SYSTEM 2 7-12.7.1 Design Requirements 2 7-I

    _ 2.7.2 System Description 2.7-3| 2.7.3 Testing 2.7-44! 2.7.4 Mission Resu]ts 2 7-842.7.5 Conclusions and Recommendations 2.7-14! vt_

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    AIRLOCK MODULE FINAL TECHNICAL REPORT MDC E0899 VOLUME IITABLE OF CONTENTS VOLUME I AND II

    Z.8 SEQUENTIAL SYSTEM z.8-I2.8.1 Pay]oad Shroud Jettison Subsystem 2.8-52.8.2 ATM Deployment Subsystem 2.8-192.8.3 Discone Antenna Deployment Subsystem 2.8-282.8.4 Power Control Subsystem 2.8-322.8.5 Radiator Shield Jettison/RefrigerationSubsystemActivation 2.8-362.8.6 OWS Venting Subsystem 2.8-402.8.7 OWS Meteoroid _hield Deployment Subsystem 2.8-472.8.8 OWS SAS Deployment Subsystem 2.8-492.R.9 ATM SAS Deployment/CanisterRelease Subsystem 2.8-532.8.10 ATM Activation Subsystem 2.8-372.8.11 MDA Venting Subsystem 2.8-602.9 INSTRUMENTATIONSYSTEM 2.9-12.9.1 Design Requirements 2.9-I2.9.2 System Description 2.9-32.9.3 Testing 2.9-262.9.4 Mission Results 2.9-352.9.5 Conclusions and Recommendations 2.g-41

    VOLUME II2.10 COMMUNICATIONS SYSTEM 2.10-12.lO.l Audio Subsystem 2.10-62.10.2 Data Transmission and Antenna Subsystem 2.10-232.10.3 Digital Command Teleprinterand Time ReferenceSubsystem 2.10-4l2.10.4 Rendezvous and Docking Subsystem 2.10-672.11 CAUTION AND WARNING SYSTEM 2.11-I2.11.1 Design Requirements 2.11-22.11.2 System Description 2.11-32.11.3 Testing 2.11-152.11.4 Mission Results 2.]1-212.11.5 Conclusions and Recommendations 2.11-242.12 CREW STATION AND STOWAGE 2.12oi2.12.1 Internal Arrangement and In-Flight MaintenanceProvisions 2.12-I2.12.2 Controls and Displays 2.12-11

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    AIRLOCK MODULE FINAL TECHNICAL REPORT MDC E0899 VOLUMEITA::LL ,JF CONTENTS VOLUME II CONTINUED

    2.i_._' VlSlbli_)' 2.12-202.12.4 L_tra Venlcular Activity 2.12-232.12.5 Lighting 2.12-332.i2.6 Stowage 2.12-492.13 CREW TRAINERS 2.13-I2.13.1 ;_ASATrainer 2.13-I2._3.2 Zero-G Trainer 2.13-132.1_.3 Neutra; _uoyancy Trainer 2.13-16. _3.4 SKylab Systems Integration Equipment 2.13-273.]a EXP[RIMENTS 2.14-1

    >

    2 14.1 M509 Nitrogen Recharge Station 2.14-I2 14.2 $193 Experiment 2.14-52 14.] b02_ Experiment 2.14-72 14.4 $230 Experiment 2.14-92 14.5 Radio Nolse Burst Monitor 2.14-112 14.6 Conclusionsand Recommendations 2.14-i22.15 GROUND SUPPORT EQUIPMENT 2.15-I2.15.1 GSE Categories and Classifications 2.15-43.15.2 GSE Developmentand Design Requirements 2.15-52.15.3 GSE Design Description 2.15-II3.15.4 GSE Certification 2.15-482.15.5 Conclusions and Recommendations 2.15-522.16 SYSTEMS SUPPORT ACTIVITIES 2.!b-I2.16.I ElectromagneticCompatibility Requirements 2.16-I2.16.2 Sneak Circuit Analysis 2.16-92.16.3 Maintenance Technology Support 2.16-122.16.4 Program Spares Support 2.16-16

    SECTION 3 RFLIABILITY PROGRAM 3-13.1 METHODOLOGY 3-I3.2 DESIGN EVALUATIOP_ 3-23.3 SUPPLIER EVALUATIOd 3-II3.4 TEST REVIEW 3-113.5 NONCONFORMANCE REPORTING, ANALYSIS, ANDCORRECTIVE ACTION CONTROL 3-13

    3.6 ALERT INVESTIGATIONS 3-17

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    AIRLOCK MODULE FINAL TECHNICAL REPORT uDc E0899 VOLUME IITABLE OF CONTENTS V_OLUMEII CCNTINUED

    ).I MISSION RFLIABILITY 3-193.8 CONCLUSIONS AND RECOMMENDATIONS 3-19

    SECTION 4 SAFETY PROGRAM 4-!4.] GROUND PEESONNEL AND CREW SAFETY 4-I4.2 INDUSTRIA,.SAFETY 4-94.3 CONCLUSIONSAND RECOMMENDAT!ONS 4-11

    SECTION 5 TEST PHILOSOPHY 5-I5.1 IEST REQUIREMENTS 5-I5.2 VERIFICATION TEST PHILOSOPHY 5-65.3 U-I VERIFICATION TESTING 5-225.4 U-2 VERIFICATION TESTING 5-365.5 MISSION SUPPORT TESTING 5-385.6 CONCLUSIONS 5-39

    SECTION 6 ENGINEERING PROJECT MANAGEMENT 6-I6.1 PLANNING AND SCHEDULING 6-36.2 ENGI,,EERINGREVIEWS 6-96.3 PROJECT REVIEWS 6-156.4 ENGINEERING REPORTS 6-206.5 INTERFACE COORDINATION 6-236.6 CONFIGURATIONMANAGEMENT 6-31

    SECTION 7 MISSION OPERATIONS SUPPORT 7-I7.1 MISSION OPERATIONS PLAN 7-27.2 MISSION SUPPORT ORGANIZATION 7-37.3 MISSION SUPPORT FACILITIES 7-67.4 MISSION SUPPORT ACTIVITY 7-297.5 CONCLUSIONS AND RECOMMENDATIONS 7-43

    SECTION 8 NE_JTECHNOLOGY 8-I

    J

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    AIRLOCK MODULE FINAL TECHNICAL REPORT MUC E0899 VOLUME IITABLE OF CONTENTS VOLUME II CONTINUED

    SELTIO'd_ CONCLUSIONS 9-I9.] AIRLOCK MISSION PERFORMANCE 9-I9.2 AIRLOCK END-OF-MISSION SYSTEMS STATUS 9-39.3 AIRLOCK PROGRAM "LESSONS LEARNEG" 9-4

    APPL;IDIXA AIRLOCK COrlTROLAND DISPLAY PANELS A-lAPPENDIK 5 MATRIX OF TE3TING REQUIRED TO QUALIFY AIRLOCKEQUIPMENT B-IAPPL:_blAc: DEVELOPMENTAND QUALIFICATIOr_TEST REQUEST INDEX r lAPPErIDI

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    AIRLOCK MODULE FINAL TECHNICAL REPORT MDC E0899 VOLUME II

    LIST OF FIGURES

    ,I(,lJrlO. TITLE PAGEI-I Airlock Module Jeneral Arrangement 3-3I-_ Airl_ck Components I-4l-j Skylab Cluster Configuration - Manned Mi_sior 1-5I-4 Skylab Launch Configurations 1-6_-5 Skylab SL-I and SL-2 Launches 1-7;-5 Skylad Mission Profiles I-82.1-I Spend Stage Experiment Support Module (SSESM) 2.1-22.1-2 wet Workshop Confiquration Evolution from Spent Stage

    Experiment Support Module 2.1-42.1-3 Orbital Wet Workshop Configuration (Unmanned Launch) 2.1-52.1-4 _pollo ApplicationsProgram - Wet Worksnop Configuration 2.1-72.1-_ Airlock Module Arrangen_nt (AAP-2) 2.1-82.1-6 Workshop Mission Profile (AAP) 2.1-92.1-7 Airlock Weight Growth History 2.1-II2.2-I Airlock Module 2.2-22.2-2 STS and Radiators 2.2-52.2-3 Tunnel Assembly 2.2-72.2-4 InternalHatch 2.2-82.2-_ EVA Hatch 2.2-I02.2-6 Flexible Tunnel Extension 2.?-II2.2-7 Support Truss Assembly 2.2-122.2-8 Deployment Assembly 2.2-132.2-9 _TM Ri9idizing Mechanism 2.2-142.2-10 Deployment Assembly Rotation Mechanism 2.2-152.2-II DeploymentSystem Release Mechanism 2.2-162.2-12 DeploymentSystem Pyro System Schematic 2.2-172.2-13 Deployment System Trunnion Mechanism 2.2-182.2-'4 DeploymentSystem Latching Mechanism 2.2-202.2-15 Fixed Airlock Shroud 2.2-212.2-]6 AM/MDA/DA Mechanical Systems Test Flow 2.?-252.2-17 AM, AM/MDA, and DA Stacking and Alignment 2.2-262.2-18 Fixed Airlock Shrnud Maximum Daily Temperature 2.2-32

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    AIRLOCK MODULE FINAL TECHNICAL REPORT MDC Eoe99 VOLUME IILIST OF FIGURES CONTINUED

    FIGURENO. TITLE PAGE2.3-I WPi,;nt Mon_.rlng Plan 2.3-22.!-2 AI, Iu,.K WelgnL History 2.3-32.3-3 WeIUhi_g _nJ Center of Gravity Determination Flow 2.3-42.3-4 Airlock Module Actual Weight and Balance Results versusCalLu!ated 2.3-52.3-.5 U-i _aunch Weight versus Maximum Speclfication Weight 2.3-62.4-I TF__,r:.;_]Contrc! Interface 2.4-22.4-? Thermal Design :;ata 2.4-62.4-3 FREPDesign Maneuvers 2.4-72._-4 Control Moment Gyros Desaturation Maneuvers 2.4-72.4-5 Kuhoutek Comet Viewing Design Maneuvers 2.4-82.4-6 Thermal Control System Design Requirenmnts 2.4-82.4-7 External Design Heat Load Conditions - Orbital 2.4-102.4-8 Internal Design Heat Loads 2.4-]I2.4-9 AM Compartment Heat Loads 2.4-122.4-10 External Surface Temperature Profile During Launch andAscent 2.4-142.4-I] Coolant System 2.4-]62.4-12 ECSControl Panel 203 2.4-172.4-13 Coolant System Flow Performance 2.4-182.4-14 Typical Coolant Reservoir Characteristics 2.4-202.4-15 Co_dplaLe Mounted Equipment 2._-222.4-16 Coldplate Locations 2.a-242.4-17 Pad and VAB Ground Cooling System 2.4-252.4-18 Pre-Liftoff Cooling Requirements 2.4-272.4-]9 Ground Coo]ing Requirements for a Hold After Ferminationof Normal Ground Cooling 2.4-2 Q2.4-20 Ground Cooling System Coolant Volume CompensatorCharacteristics Curves _.4-302.4-2! Radiator Capacity 2.4-312.4-22 Radiator Performance for EREPManeuvers (60 Arc Pass) 2.4-332.4-23 Radiator Performance for EREPManeuvers (120 Arc Pass) 2.4-342.4-24 Radiator Stretchout - Looking Outboard 2.4-352.4-25 Thermal Capacitor 2.4-362.4-26 Coolant System Performance 2.4-372.4-27 SL-4 Coolant Reservicing 2.4-39

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    AIRLOCK MODULE FINAL TECHNICAL REPORT MDC E0899 VOLUME IILIST OF FIGURES CONTINUED

    fiG'J_ NO. TITLE PAGE2.4-28 Coolant Reservicing Pressure Characteristics 2.4-41Z.4-29 Coolant Reservicing Mass Characteristics 2.4-422.4-30 ATM C&D Panel/EREP Cooling System 2.4-432.4-3] EREP Electrical Loads (60 Arc Pass) 2.4-442.4-32 EREP Electrical Loads (120_'Arc Pass) 2.4-442.4-33 Power Conditioning Group Waste Heat - Two Solar ArrayWings 2.4-472.4-34 Power CondiLioningGroup Waste Heat - Solar Array Wing #1 2.4-482.4-35 Dredicted Battery Temperatures - Two Solar Array Wings 2.4-492.4-36 Predicted Battery Temperatures - Solar Array Wing #1 2.4-492.4-37 AM/MDA Thermal Coating Design Values 2.4-502.4-38 DA apd FAS Thermal Coating Design Values 2.4-512.4-39 Vehicle Thermal Insulation 2.4-532.4-40 Equipment Thermal insulation 2.4-552.4-41 Wall Heater Location/ThermostatInstallation 2.4-572.4-42 Molecular Sieve Overboard Exhaust Duct Heater 2.4-592.4-43 Thermal Control Subassembly Tests 2.4-652.4-44 Coolant System Test History - MDAC-E 2.4-672.4-45 ATM C&D Panel/EREPCooling System Test History - MDAC-E 2.4-682.4-46 Coolant System Requirement Verification 2.4-742.4-47 Coolant System Pump/InverterFlow Tests - MDAC-E 2.4-762.4-48 Coolant System Pump/Inverter Flow Tests - KSC 2.4-772.4-43 ATM C&D Panel/EREPH20 Cooling System RequirementVerification 2.4-782.4-50 Thermal Control Coating Requirement Verification 2.4-792.4-51 AM U-] Radiator Solar Reflectance Test Results - KS 2.4-802.4-52 Thermal/MeteoroidCurtains Gold Coated Surface EmissivityMeasured at MDAC-E 2.4-812 4-53 Coolant F]owrate 2.4-I002 4-54 Coolant System Pump Inlet Pressures 2.4-I012 4-55 Coolant System Coo]anol Mass 2.4-I022 4-56 Coolant Loop Heat Loads 2.4-I052 4-57 Coolant Temperatures During Radiator Cooldown 2 4-I062 4-58 Thermal Capacitor Performance 2.4-I072 4-59 SL-2 Radiator/Thermal Capacitor Temperatures 2.4-1082 4-60 SL-3 Radiator/ThermalCapacitor Temperatures 2.4-I08

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    AIRLOCK MODULE FINAL TECHNICAL REPORT MDCE0899 VOLUME tiLIST OF FIGURES CONTINUED

    FIGURENO. TITLE PAGE2.4-61 SL-4 Radiator/Thermal Capacitor Temperatures 2.4-1082.4-32 Radiator/_hermal Capacitor Temperatures During a

    Kohoutek Viewing Maneuver 2.4-1102.4-63 Radiator/Thermal C_pacitor Temperature During an EREPZ-LV Maneuver 2.4-1102.4-64 Effect of SL-I Attitude on Airlock Module Temperature 2.4-1152.4-65 STS Wall Temperature 2.4-1162.4-66 STS Gas Temperature at Mole Sieve - Compressor Inlet 2.4-1172.4-67 gAS Sk!_ Temperature Solar Inertial Attitude 2.'a-I182.4-68 02 Tank Temperature - Solar Inertial Attitude 2.4-1132.4-69 N2 Tank Temperature - Solar Inertial Attitude 2.4-1202.5-I Airiock Environmental Control Interface 2.5-?2.5-2 Gas System 2.5-102.5-3 Airlock Cluster Purge and Cooling Requirements 2.5-112.5-4 STS Window Assembly 2.5-132.5-5 Ozygen and Nitrogen Tanks 2.5-142.5-6 02/N 2 Control Panel 225 2._-162.5-7 Cabin Pressure Regulator Flowr_te Characteristics 2.5-212.5-8 Control and A]arm Ranges for Two Gas Control Systems 2.5-222.5-9 Forward Compartment Pressure Relief Valve 2.5-232.5-10 Atmospheric Control System 2.5-242.5-11 Dewpoint Temperature During Activation 2.5-252.5-12 Cluster Dewpoint Temperature Range After Activitation 2.5-262.5-13 ECSControl Panel 203 2.5-282.5-14 ,,_olecular Sieve Condensing Heat Exchanger Control Panels 2.5-292.5-15 Molecular Sieve Condensing Heat Exchanger Air Flow Valve 2.5-30

    ; 2.5-]6 Condensing Heat Exchanger 2.5-31I 2.5-17 Single Molecular Sieve System 2.5-33I 2.5-18 Molecular Sieve Vent Valves and Bed Cycle N2 Supply Valves 2.5-36

    2.5-]9 Molecular Sieve A Valve Control Panels 226 and 228 2.5-37.5-20 Molecular Sieve Operating instructions 2.5-382.5-21 PPCO2 Sensor 2.5-392.5-22 Molecular Sieve A PPCO2 Sensors 2.5-402.5-23 PPCO2 Sensor Recharge Require,"ts 2.5-aI2.5-24 Tunnel Stowage Container (_) 2.5-42

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    : ._k_ :_0 TITLE _r2._ 2_ 'VentilationFiowrates Delivered to OWS 2.5-43Z.6-26 Ventilation Flowrates Delivered to MDA 2.5-:_42.5-Z7 Atr_spheric Cooling Capability - Condensing Heat ExchangerFlow Diverted to OWS 2.5-45L._-2_ Atmospheric Cooling Capability - Condensing Heat ExchangerFlow Diverted to MDA ?.5-462.5-29 AM Condensate System P..-48_.5-30 Condensate Control Panel 216 2.5-492.5-31 Effect of Cabin Gas Leakage on OWS HolJing TankPressurization 2.5-502.5-32 AM Condensate Tank Pressure Buildup 2.5-512.,-33 Water Separator Plate Servicing 2.5-53._-3_ In-fl,ghtWater Servicing 2.5-54_.5-3S AtmDspheric Control System Test History - MDAC-E 2.5-65._,-36 Gas System Test History - MDAC-E 2.5-66_.5-37 Condensate System Test History - MDAC-E 2.5-672.5-36 ECS Gas System Roquirement Verification 2.5-72_'.5-39 ECS AtmosphericControl System RequirementVerification 2.5-782.,_,-10 ECS Condensate System Requirement Verification 2.5-812.5-41 Compartment Differential Pressures DJring Ascent 2.5-892.5-42 Prelaunch Loading of Airlock Module 02 and N2 Tanks 2.5-902.5-43 02 and N2 Consumable Usage Summary 2.5-912.5-44 Gas System Regulated 02 Pressures 2.5-922.5-_5 Gas System Regulated N2 Pressures 2.5-93Z.5-46 Regulated N2 Pressures During SL-3 2.5-942.5-47 Regulated N2 Pressures During SL-4 2.5-95_..5-48 Cluster PressurizationPrior to SL-3 2.5-962.5-_.9 Cabin Total and Oxygen Partial Pressure Control 2.5-I002.5-50 SL-2 Dewpoint History 2.5-I02Z.5-51 Sl.-3Dewpoint History 2.5-I032.5-52 SL-4 Dewpoint History 2.5-I042.5-53 Molecular Sieve A Inlet CO2 Partial Pressure 2.5-I062.5-54 Molecular Sieve Performance 2.5-I072.5-55 Summary of Molecular Sieve Bed Bakeouts During Flight 2.5-I0}_2.5-56 Airlock Modu',_Fan Performance 2.5-I092,5 5/ InterchangeDuct Fan Flowrate 2.5-III

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    AIRLOCK MODULE FINAL TECHNICAL REPORT MDC Eg899 VOLUME II!!ST OF FIGUPES CONTINUED

    FIGURE NO. TITLE PAGE2.5-58 Aft Compart:nentCab1r,i_cot_xchanger Fan Flowrate 2.5-I122.5-59 Heat Removal from Cabin Atmosphere 2.5-I142.5-60 SL-2 Condensdte System Activation 2.5-I152.5-61 Condensaze Syste:ePressure During EVA on DOY 158 2.5-I162.5-62 Conaensate 3yst__ eres_,Jre3urlng OWS Ho'ding Tank Dump 2.5-1172.5-63 ,L-_:ionJens_te_/steF Activation 2.5-_182.6-i ;VA Control _dnei 2i7 2.6-5_._-2 EVA _o. i Conzroi Panel _I/ 2.6-62.6-3 ETA ;_o. 2 Control Panei 3_ 2.6-7o 6-4 Lock ComPartment Control Pane] 316 2.6-82.6-5 Airlock Suit Cooling System 2.6-102.6-i Lighting, Caution and Warning Control Panel 207 2.6-112.6-7 System 1 LCG Reservoir Pressure Valve Panel 223 2.6-132.6-8 LSU Stowage in AM 2.6,-I42.6-9 Liquid/Gas Separator 2.6-152.6--10 Funnel Stowage Container 305 2.6-162.6-ii SUS Water Flowrate Performance 2.6-172.6-12 Suit Cooling S_stem Performance 2.6-192.5-i3 Suit Cooling System Performance 2.6-202.6-]4 Suit Coolln9 System Performance 2.6-222.6-15 Lock Depressurization Valve and Forward Hatch 2.6-252.6-16 Lock/Aft Compartment Ventinq for EVA 2.6-262.6-|7 EVA Lock/Aft Compartment Repressurization 2.6-262.6-18 EVA Lock/Aft Repressurization Profile - Alternate 2.6-272.6-19 Suit Cooling System Test History - MDAC-E 2.6-342.6-20 Suit Coolin9 System Requirement Verification 2.6-382.6-21 EVA/IVA 02 Sdpply System Requirement Verification 2.6-402.6-22 EVA/IVA Gas Delivery System 2.6-422.6-23 EVA Lock Pressure Control Valve Requirement Verification 2.6.-432.6-24 Summary of Suit Cooling System Operation 2.6-472.6-25 Suit Cooling System Performance - DOY 158 EVA 2.6-482,6-26 Suit Cooling System Performance - DOY326 EVA 2.6-492.7-I Module Layout - Solar Array Group 2.7-52.7-2 AM EPS Equipment Location 2.7-6

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    AIRLOCK MODULE FINAL TECHNICAL REPORT _DC E0899 VOLUME ,JLIST OF FIGURES CONTINUED

    _,D_ _,,_ TITLE PAGE. "'_y_'_. _'2 j . _ __-_2 /-3 PCG Component Location - Battery Module 2.7-7

    7-4 Typical PCG Circuit - Controls and Instrumentation 2.7-87-5 Battery Charger Functional Block Diagram 2.7-102 7-6 Ampere-Hour Return Factor versus Battery Temperature 2.7-122 7-7 Battery Charging Mode Curves 2.1-142.7-_ Voltage Regulator Block Diagram 2.7-]72./-9 Voltage Regulator and Current Characteristics 2.7-I_2.7-10 Typica] Voltage Regulator Total Output Characteristic 2.7-,202.7-II Battery Output Function Diagram 2.7-222.7-12 SimplifiedOrbital Assembly Power DistributionDiagram 2.7-242.7-13 Simplified Bus Control and Monitor Diagram 2.7-26

    7-14 Shunt Regulator 2.7-312.7-]5 Continuous PCG Power DeterminationDiagrams 2.7-35".7-16 Battery State-of-Chargeversus Orbital Time for VariousLoad Conditions 2.7-363.3-17 Regulator Output Voltage and Current Curves 2.7-40._.7-1_ AM EPS Testing History 2.7-453.7-19 MDAC-E Battery Test Parameters 2.7-59,'._-20 Maximum Load Capabilities of PCG's 2.7-642.I-21 []ectrical Power System - SST Flow Diagram 2.7-732 7-22 Calculated AM EPS Bus Power Capability versus Day-of-Year 2.7-_62 l-Z3 AM EPS Bus Power for SL-2 to SL-3 Storage Period 2.7-882 7-24 AM EPS Bus Power tapability versus Day-of-Year - SL-3 Mission 2.7-_9Z /-25 AM EPS Bus Power for SL-3 tO SL-4 Storage Period 2.7-922 7-26 AM EPS Bus Power for SL-4 Manned Mission 2.7-942 /-27 Typical PCG Orbital Parameter Variations 2.7-97_.1-2}_ Limitation of AM Battery Charge VoltageSL-2 and 3 Mission Composite 2.7-992.7-29 Ampere-Hour Meter State-of-Charge Integration 2./-I007-30 Battery St_Jte-of-CharqeIntegration 2 7-104. ,

    /.7-71 _)CG=3 Bat:ery State-of-ChargeAccuracy 2.7-I062.7-_2 PCG =8 Bdtcery State-of-ChargeRecovery 7.7-110._.7-33 SL-2 Mission Composite AM Battery Discharge Characteristic Z.7-1112.7-34 PCG :6 Inflight Capacity Discharge 2.7-1152./-35 PCG =C_Inflight Capacity Discharge 2.7-116

    xvi

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    FIGURE NO. TITLE PAGE2.7-36 SL-3 Composite AM Battery Discharge Characteristic 2.7-I172./-37 SL-.iComposite AM Battery Discharge Characteristic 2.7-I19Z 7-38 PCG -6 inflight Capacity Discharger 2.7-1202 7-3g Typical 3800 Cycle Discharge Profile for IndicatedBatteries 2.7-122Z 7-40 Typical 3_00 Cycle Discharge Profile for IndicatedBatteries 2.7-1232 7-41 Typical Volzage Regulator Input and Output Voltages 2.7-1242 7-_2 AM Bus Regulation Curves (Typical) 2.7-1262 7-43 SAS --_C,,rrentPaths 2.7-137L 7-44 Simul_ted "SAS =4 Return Wire Short" Test Results 2.7-142.;-i SL-I and SL-2 Major Sequential Events 2.8-2

    2.;_-L ILJ/OWSSwitch Selector System 2.8-32.8-3 Discrete Latch Actuator System 2.8-62.8-4 Payload Shroud Electrical Ordnance 2.8-72.8-5 Payload Shroud Thrusting Jolnt System 2.8-82.8-6 Payload Shroud Component Location 2.8-I02.8-7 Payload Shroul Electrical-Commands/Functions 2._-II2.8-8 Payload Shroud Electrical Jettison Diagram 2.8-132.8-9 System Testing - Payload Shroud Jettison Subsystem 2.8-142.8-I0 Sunu;_aryf Launch Site Significant Ordnance and Deplo_nnentProblems 2.8-152.8-II Payload Shroud Jettison 2.8-162.8-12 Typical EBW Firing Unit Charge/Trigger Curve (Telemetry Data) 2.8-172.8-14 Payload Shroud Jettison Sequence 2.8-18__.8-14 ATM Deplo_nent Electrical Commands/Function,, 2.8-212.8-15 ATM Deployment Diagram 2.8-222.8-16 System Testing ATM Deployment Subsystem 2.8-232.8-17 ATM Deployment 2.8-252.8-18 Typical EBW Firing Unit Charge/Trigger Curve (Telemetry Data) 2.B-262._I-19 ATM Deployment Sequence 2.8-26_.8-20 Discone Antenna Deployment Diagram 2.8-292.8-2] Discone Ante ,has 2.8-302.8-22 Deploy Bus Control Diagram 2.8-332.8-23 Sequential Bus Control Diagram 2.8-3t2.8-24 Refrigeration System Radiator Shield Jettison Diagram 2.8-372.B-25 Refrigeration System Radiator Shield Jettison 2.8-37

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    FIGURE NO. TITLE PAGE2._-26 Refrigeration System Control Diagram 2.8-382._-27 OWS RefrigerationRadiator Temperature 2.8-392._-28 O!JSHabitation Area Vent Valves 2.8-4]2.C-29 OWS Waste Tank Vent Diagram 2.8-41_._-30 OWS Pneumatic Sphere Dump Diagram _._ 422._-31 OWS Solenoid Vent Valves (Habitation Area) Diagram 2.b-432.;_-32 OWS Habitation Area Vent 2.8-442._-33 OWS Waste Tank Vent 2.8-45_._-34 Pneumatic Sphere Dump 2.8-462.3-35 Meteoroid Shield Deployment Diagram 2.8-48_._-36 OWS Beam Fairing DepiolmlentDiagram 2.8-502.B-37 OWS Wing Deployment Diagram 2.8-51Z.d-38 ATM SAS Deployment/ATMCanister Release 2.8-542.3-39 ATM SAS/Canister- Commands/Functions 2.8-552.8-40 ATM Activatlon/Control 2.8-582._)-4| Typical AM CRDU Circuit 2.8-592._-42 MDA Vent Valve Functions 2.8-612._-43 Typical Vent Valve Control Circuit 2.8-61?.4-44 MDA _ent Valve Operation 2.8-63Z.9-| S_;,a Workshop InstrumentationSystem 2.9-22.9-2 InstrumentationRegulated Power Subsystem ?.9-122.9-3 PCM Multiplexer/Encoder 2.9-142.9-4 PCM Multiplexer/EncoderChannel Capability 2.9-152.9-5 Recorded Data Signal Flow 2.9-182.9-6 Mission Data Processing Flow (DRR Magnetic Tape) 2.9-27Z.9-7 InstrJmentationSystem Test Flow (MDAC-E) 2.9-292.9-8 InstrumentationSystem Test Flow - KSC 2.9-342.9-9 i_strumentationSystem Summary - First Mission 2.9-372.'J-IO InstrumentationSystem Summar_ - Second Mission 2.9-392.9-11 InstrumentationSystem Summary - Third Mission 2.9-402.10-I Communications System 2.10-32.]0-2 Communication,System Test Flow - MDAC-E 2.10-42.|0-] Communi_dtions System Test _]ow - KSC 2.10-52.10-4 Orbital %sembly Audio Subsystem 2.10-9

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    FIGURE NO. TITLE PAGE2 ]0-5 Airlock Data Transmission and Antenna System 2.10-232 I0-6 DCS, Teleprinter, and TRS Subsystem 2.10-412 10-7 Command Code Format 2.]0-442 I0-8 Teleprinter Subsystem Data Format 2.10-542 I0-9 Teleprinter System Characters and Test Message 2.10-562 ]O-lO VHF Rang ng Subsystem 2.10-582.10-1] Tracking Lights 2.10-712.10-12 Docking Lights 2.10-732.11-I Cluster Caution and Warning System 2.11-42.11-2 Caution and Warning System Controls and Displays 2.11-52.11-3 Caution and Warning System Parameter Inputs 2.11-82.11-4 Caution a,ldWarning System Test Flow - MDAC-E 2.11-162.12-I Internal Arrangement (+Y, -Z) 2.12-22.12-2 Internal Arrangement (-Y, +Z) 2.12-32.12-3 Panel Locations (+Y, -Z) 2.12-132.12-4 Panel Locations (-Y, +Z) 2.12-142.12-5 Control and Display Panel References 2.12-152.12-6 Main Instrument Panel 2.12-I.2.12-7 EVA Equipment (+Y, -Z) 2,12-342.12-8 EVA Equipment (-Y, +Z) 2.12-252.12-9 EVA Handrails and Lighting 2.12-262.12-I0 LSU Stowage 2.12-272.12-II EVA Provisions 2.12-292.12-12 EVA Workstation 2.]2-302.12-]3 Lighting Provisions and Illumination Levels 2.12-342.12-14 General Illumination 2.12-362.12-15 AM/OWS Initial Entry/Emergency Lights 2.12-382.12-16 AM/MDA Emergency Lights 2.12-392.12-17 Lighting System Test History - MDAC-E 2.12-402.12-18 Status Light Sensor Versus Function 2.12-432.12-19 EVA Lights 2.12-462.12-20 Stowage Locker M168 2.12-502.12-21 Stowage Location M201 _.12-512.12-22 Stowage Lncker M202 2.12-52

    i 2.12-23 Stowaqe Locker M208 2.12-51I xix

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    FIGURE NO. TITLE PAGE2.1Z-24 Stowage Locker M30] 2.12-54?.12-25 Stowdge Locker M303 Z.12-55?.i2-2& Stuw,_ueLocker M305 _.12-562.1_-2/ _towage Locations M308 and M313 2.12-572.12-28 Stowage Locations M310 and M311 2.12-5F_2.12-29 Stowa'jeLocation M326 2.12-592.12-30 Film Transfer Boom/Hook Stowage 2.12-602.13-1 Early Airlock Trainer 2.13-22.13-2 The NASA Trainer 2.13-32.13-3 NASA Trainer Connector Panel 2.13-52.13-4 NASA Trainer- Initial Support Stand 2.13-52.13-5 EVA Stand Modifications 2.13-72 13-6 EVA Dev,:_opmentStand at rISFC 2.13-92 13-7 Zero-G Trainer 2.13-142 13-8 Zero-G Trainer - EVA Hatch Damper 2.13-152 13-9 Zero-G Trainer Used as a High Fidelity One-G Trainer 2.13-172 13-lO Original Neutral Buoyancy Trainer 2.13-172 13-ll Airlock Neutral Buoyancy Trainer on Rotating Dolley 2.13-192 13-12 Neutral Buoyan;y Trainer 2.13-202 13-13 Neutral Buoyancy Trainer in JSC Facility 2.13-212.13-14 Model of Neutral Buoyancy Trainer in _SFC Facility 2.13-232.13-15 Neutral Buoyancy Trainer- Crew Training 2.13-242.!3-16 Neutral Buoyancy Trainer - _Hssion Support Activity 2.13-262.14-I Experiment Locations 2.14-22.14-2 M509 Recharge Station and iiold-downBracket 2.14-42.14-3 S193 Package Installation 2.14-62.14_4 D024 Thermal Control Coating 2.14-82.14-5 $230 Experiment 2.14-I02.15-I Design Criteria for Handling Equipment 2.15-72.!5-2 Airlock in Vertical TransDorter 2.15-122.15-3 IlatedAM/MDA in Horizontal Trailer 2.15-13

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    FIGURE NO. TITLE PAGE2 15-4 FAS it_Transportc_ - Lau_ichAxis Horizontal 2.15-142 15-5 Mated DA in Transporter 2.15-152 15-6 A;_Vertical Transporter and Associated GSE 2.15-172 15-7 AM/MDA Horizontal Handling Trailer 2.15-192 15-8 Mated AM/MDA Being Loadee on Shipping Pallet 2.15-202 lS-g Fixed Airlock Shroud Transporter and Associated GSE 2.15-212 15-10 Fixed Airlock Shroud Air Shipment 2.15-212 15-li DA Transporter 2.15-232 15-12 Deployment Assembly Air Shipment 2.15-242 15-13 FAS/MDA/AM/DA/PSCylinder Stack Handling 2.15-252.15-14 Access and Hoisting Provisions 2 15-272.15-15 Payload Shroud Access Platform Trial Fit 2 15-282.15-16 AM/MDA Electrical/ElectronicGSE - MDAC-E 2 15-302.15-17 02/N2 Servicing and AM/MDA N2 Purge 2 15-412.15-18 02/N2 Servicing and AM/MDA N2 Purge Schematic 2 15-432.15-19 Airlock Ground Cooling 2 15-442.15-20 Airlock Ground Cooling Schematic 2 15-452.15-21 Altitude Chamber Fire Suppression 2.15-472.16-I Electro Magnetic Compatibility Test Flow 2.16-52.16-2 Tools and In1"lightSpares 2.16-133-I Failure Mode and Effect Analysis Report - Sample Page 3-43-2 Critical Item List Report - Sample Page 3-53-3 NonconformanceReporting,Analysis and Corrective Action 3-143-4 MDAC-E Alert Summary 3-18

    + 5-I Test Program Trade Study 5-3.,-2 Airlock Test Program Trade Study Results 5-35-3 Test Program Documentation 5-5

    5-4 Process for Qualification Program Definition 5-7-5 Flight Hardware Criticality Category 5-8

    5-6 Suggested Number of Qualification Test Articles 5-85-7 Endurance Testlng 5-95-8 Overall Planned Test Flow 5-135-9 Planned Test Flow at MDAC-E 5-145-I0 Total Acceptance Test Publications (U-I and U-2) 5-17

    XI

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    FIGURENO. TITLE PAGE5-I! Typical Major Fest Document Preparation Sequence 5-185-12 Acceptance Test Documentation Tree 5-205-_3 Generalized Overall Test Flow 5-21-_-i4 AM/MDA/FAS/L_AMating Activity 5-265-15 FAS and OA Test Fie.. -ollowing Soft-Mate Activity 5-285-16 U-I MDAC-L lzst Flow - Planned 5-295-17 U-I MOAC-ETest Flow - Actual 5-31b-18 U-I Latmcn Site Test Flow - Planned 5-32b-19 U-I Launch Site Test Flow - Actual 5-355-20 U-2 MDAC-ETest Flow - Actual 5-376-I Engineering _-laster Sciledule - Sample 6-46-2 Acceptance Test >taster Schedule - Sample 6-66-3 Engineering Job S,leet Flow Plan 6-86-4 Syst_m/Suosyste_:, Design _eviews 6-96-5 Uerification Documentation Relationsilip 6-216-6 luterfac_ Control Document 3aseline Su_)mitcals b-246-7 F!ig,;t Ve,,icle iu_rfa_e'., 6-256-8 GSE [ nterfac..:s 6-266-9 Airlock I f_terface C_ntrol Document Ci_ange Activity 6-276-I0 Technical P.equirements Documentation 6-326-II Class [ Chanqe Flo,v Plan 6-367-I Lxample Airlock Project >lission Communications at;dResponsibillti_s (;\.i Design and Tecnnical Groups) 7-57-2 HDAC-E Hission Opt.rations Communications Facility 7-77-3 Systems Tr:_'r,d C_lar_.s CommCenter 7-87-4 Systems Schematic_ and Trend Charts - CommCenter 7-97-5 U-2 BacLup Fiiqnt _iardw,lre 7-]37-6 Skylaa STU/STD,I Jloc_, D_a(iram 7-167-7 AM/OWS/ATH/MDASi_,,u]a_or 3lock Diagram 7-177-8 STU/STD, CommandControl Console 7-187-9 STLI/STD, Dat,d Acq'Jisi tion System 7-18/-lO TV _quipmenL and ._-_and Sround Statio,l 7-187-ll CommandControl Ccr_solu In;)ut/Output L{Ioc._ Diaqram 7-20

    i Z- 1Z DaLa Presenta ti on Teclmi ques 7-_i"',-13 .'.irloc; [CS/ICS 5[U Capabilities 7-25

    t xxii

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    FIGURE NO. TITLE PAGE7-14 ECS/TCS STU Cabin Environment Chamber 7-267-15 ECS/TCS STU External EnvironmentChamber Simulation Setup 7-267-16 __CS/TCSSTU Test Configuration 7-277-17 Vendors Supporting MDAC-E Mission Operations 7-327-18 Airlock Project Hission Operations Support Coverage 7-338-I Published NASA Technology 8-28-2 Juployment Assembly Latching Mechanism 8-2

    This document consists of the followingpages:VOLUME I

    Title Pageiii through xxiii 2.4-I through 2.4-124l-I through 1-22 2.5-I through 2.5-123

    2.l-I through 2.1-12 2.6-I through 2.6-562.2-I through 2.2-32 2.7-I through 2.7-1462.3-I through 2.3-6 2.8-I through 2.8-64

    2.9-I .'_'hrough 2.9-44

    VOLUME IITitle Page 7-I through 7-44iii through xxiii 8-I through 8-42,10-I through 2.10-78 9-I through 9-14

    2.11-1 through 2.11-26 A-l through A-202.12-I through 2.12-64 B-l through B-142.13-I through 2.13-28 C-l through C-242.14-I through 2.14-12 D-l through D-122.15-1 through 2.15-54 E-I through E-162.16-I through 2.16-18 F-l through F-12

    3-1 through 3-20 G-1 through G-84-I through 4-12 H-I through H-85-I th,'ough5-40 l-I through 1-46-1 through 6-42 J-Illthrough J-65

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    I.I PURPOSEAND SCOPEhe AirlockModulewas one elementof a very ;bccessfulSkylabProgram. Thisreportdocumentsthe technicalresultsof the AirlockProject,i.e.,the conceptlon,development,and verificationof f!,gntand groundsupporthardware,and includes

    : the controllingprogramfunctionsthat resultedin the on-scheduledeliveryof aflightworthyspacecraft.Problemsand theirsolution_are alsodocumentedso thatexperienceoeinedduringall phasesof this pregrammay be used as buildingblocksfor futurespacecraftprograms.

    o._ Module each systemi.describedo providea fullunderstandingof the Airl _'in termsof requirements,onfiguration,_rification,and missionperformance.

    To providea betterunderstandingof the open-endedtest concept,AilocktestphiIasophyis discussedthroughits evolutioninto the final,implementedtestplan.

    To demonstratethe importanceof managementcontrolfunctionsto a succe_sfai_rogram,thetechnicaldisciplinesof reliability,safety,and engineeringschedulin9and controlare discussed.

    To illustratethe methodand extentof activityrequiredto support_ long-term,complexspaceoperationsystem,missionoperationsupportis detailed.

    To allowfurtherrefinementof the Nation'sspaceefforts,conclusionsderivedfrom total programresultsare discussedand recommendation3or futureprogramsaremade.

    Additionally,directsupportof theMannedSpaceFlightCenter(MSFC)andotherNASA centers,duringbothprelaunchand missionoperatiuns,is summarized,as is the r_sultsof the New TechnologyReportinoProqram.

    The AirlockProgramContract(NAS9-6555)coversthe AirlockModule,includingthe ATMDeploymentAssembly(DA),the FixedAirlockShroud(FAS),thePayload_', Shroud(PS),and all associatedGroundSupportEquipment(GSE)and trainers. The_e

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    ei_m_.nts,with one exception of the Payload Shroud, were designed, fabricated, andverifipd at the McDonnell Douglas, St. Louis, Missouri Facility and are covered inthis report (MDC _eDort E0899, Airlock Module Final Technical Rt:port).

    The Payload ohroud was designed, fabricated, and verified at the McDonnellDouglas, Huntington Beach, California Facility and is discussed in MDC Report G4679A,Payload Shroud Final Technical Report.

    These two reports, MDC Reports E0899 and G4679A, together comprise the SkylabAirlock Project Final Technical Report.

    1.2 SUMMARYThe Airlock Module (AM), Fixed Airlock Shroud (FAS),Deployment Assembly (DA),

    and Payload Shroud (PS), shown in Fiqures l-l and I-2 , and all associatedtrainers and Ground Support Equipment were designed, fabricated and verified underNASA Contract as basic elements of the 3kylab cluster, shown in Figure I-3 Thisorbiting laboratory was launched aboard a Saturn V launch vehicle on 14 May 1973and was subsequentlymanned by crews launched in modified Apollo Command andServicq Modules on Saturn IB launch vehicles (shown in Figure m-4 and FigureI-5 ). The Skylab suppnrted solar, celestial, and earth observations; medical,scientific,engineering,and technology experiments,during three manned missionsof 28, 59 and 84 days, respectively, from 25 May 1973 through 8 February 1974.As shown in Figure I-6 , the active operation of the as-f ,inmission exceeded theplanned mission by 3! days and total mission duration exceeded that planned by35 days.

    1.2.1 Airlock FeaturesThe AM provided the followinn features:m Interconnectinqpassage between MDA and OWS,e Lock, hatch and suoport system for extravehicularactivity (Ev_).m Purification of the Skylab atmosphere.o Thermal control of the Skv_,aDatmosphere (coolin_only for _4DAand OWS).e Atmospheric supply and control.e Apollo Telescope Mount (ATM) launch support and orbital deployment.e Payload protection durinq launch (Payload Shroud).

    i-2

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    % ,/"Launchonfi_ration Payloadhroudettisoned

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    FIGURE1-2 AIRLOCKCOMPONENTS1-4

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    1-5

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    AIRLOCK MODULE FINAL TECHNICAL REPORT MC)CE0899 VOLUME

    FEET-,_oC_ , /-_'*,mPAYLOADSHROUD

    - 300 !!.._ /,--," ,';'",I_APOLLO TELESCOPE-_ OE,"O',,E,T__ .--L----___.... I' ASSEMBLY-------.L.,_-_ :'_'_MULTIPLEFIXEDAIRLOCK

    SHROUD _.L--.-'-'--AIRLOCK._ .------INSTRUIIENT UNITSM - 200

    >S-..I!STAGE ,,.,.,.-----ORBITAL............ WORKSHOP

    _a_lL_t, laL,,- 150 ,, .......S-.IVBSTAGE ," ",

    100 ,,,...-.----SATURN

    _,_ INTERSTAGES-.ICSTAGE .I--- SATURNI

    S..-IBSTAGE 50

    SL-2, 3 &4 SL-](MANND) IUNMANND)

    FIGURE1-4 SKYLABLAUNCHCONFIGURATIONS

    1-6

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    FIGUREI-5 SKYLABSL-IAND SI.-2AUNCHESI-7

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    i

    ",.)uj2=t' --o ...... .=,,-r-=_ s':I,-"- - _' I_--_-_

    _- - (:3=...-4-- ---- .co ,

    i

    N

    lllIF i lilil _,. _ ..I = 3 , I ,

    L ,.=,= I I "_i_ ,-',o I I _,,__

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    Llectr_cal power conditioning control, d,U distribution. Real and delayed time data. Cluster interco_unication. Cluste_ f,_,]t;rearning. Command system link with ground _etwork.e VHF ranging link for CSM rendezvous. Controls and displays. Teleprinter.e Experiment installationof D024 sample panels. Experiment antennas (EREP and radio noise burst monitor). ATM C&D Panel cooling.

    1.2.2 Airlock Module Weight and Dimensionse Gross AM Weiqht 15,166 lb. AM Working Volume 610 cuft.e AM Overall Length 211.54 in.

    Tunnel AssemblyLength 153 in.Diameter 65 in.Volume 322 cuft.

    Structure Transition Section (STS)Lenqth 47 in.Diameter 120 in.Volume 288 cuft.

    PressurizedAM to (IWSPassagewayLength II.54 in.

    : Diameter 42.5 in.}

    1.2.3 FAS Weight and Dimensions( e Gross Weiqht 22,749 lb.I

    e Length BO in. Diameter 260 in.

    i The FAS provided the capability of structurallysupporting the Apollo Telescopei Mount (ATM), AM, MDA, and Payload Shroud (PS) during the launch phase of thei mission. The structural shell consisted of thick skin and ring construction with

    local intercostals for structural support of the ATM Deployment Assembly (DA).

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    1.2.4 DA Weight and Dimensionse Gross Weight 3,744 lb. Length (Upper DA) 122 in.e Lengtn (Lower DA) 194 in.

    The DA consisted of two tubular truss assemblies connected by a pair of trunnionjoints which allowed the upper truss assembly to rotate through go to deploy theATM. The DA rotationsystem consisted of two redundant springs that retardedrotationand redundant deployment reels, cables, gear train and motors to pull theATM into the deployed position. A redundantpyrotechnically-operatedlatch actuatorallowed mechanical disengagement of the stabilization struts, and a sprinq-loadedlatch mechanism retained the ATM-DA in the deployed position as shown in Figure I-3.The DA included two major carrier wire assemblies to intercunnect the clusterelectrical power systems and to connect the ATM with the ATM C&D Panels in the MDA.Detailed information on Airlock structures/mechanicalsystems and on mass propertiesmay be found in Paragraphs 2.2 and 2.3, respectively.

    1.2.5 Payload Shroud (PS)The PS consisted of a cylindrica; _ction and a biconical nose section; both

    sectionswere thick skinned, ring reinforced, monocoque structures. The PS supportedthe ATM during the prelaunch and launch phases and provided ae'odynamic protectionduring launch and contaminationprotection for the AM, _A, and ATM through S-IIon-orbit retrofire. After achieving orbit, the PS was jettisoned as part of theunmanned cluster activation sequence; it was separated radially into four quadrantsvia a discrete latching system and a longitudinal thrusting joint system. Both ofthese separation systems were powered by redundantly fired linear explosive devices.

    Configurationcharacteristicsw_re: Gross PS Weight 25,473 Ibs.e PS Overall Length 674 in.

    Cylinder Length 350 in.Biconical Nose Length 324 in.

    PS Diameter 260 in.

    The PS design was verified by separation element and panel tests, discretelatching system tests, and three full-scaleseparation tests conducted by the NASAin the Plum Brook Space Power Facility vacuum chamber. In addition, the full-scalePS was installed during the vibro-acoustictesting at JSC.

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    PayloadShroudS/N 03 was launchedon Skylab1 and was subsequentlyjettisonedin-orbitwithoutproblem;all functionsperformedas plannedat thecorrectattitudeand the designedseparationvelocitywas i_artc..'.

    Completedetailsof therequirements,designconfiguration,erification,anOmissionperformanceof the PS is givenin MDC ReportG4679A,PayloadShroudFinalTechnical Report.

    1.2.6 Environme._tal_!.ThermalontrolSystems(ECS/TCS)The AM ECS/TCSconsistedof the followin9subsystems:e The gassystempermittedprelaunchpurge,storedhigh pressure02 and _2

    regulatedpressureanddistributionfor cabinat:,_osphere,nd other uses.e The atmosphericcontrolsystemprovidedmoistureremoval,carbondioxide

    and odor removal,ventilationand cabingas cooling. Moisturewasremovedfrom theclusteratmosphereby condensingheatexchangersan_molecularsieves. Carbondioxideand odorwere also removedby themolecularsievesystem. Ventilationwas providedby fansand condensin9heat exchangercompressors.Gas coolingwas providedby the condensingand cabinheatexchangers.

    The condensatesystemprovidedthe capabilityof removingatmosphericcondensatefrom the condensingheat exchangers,storingit, anddisposingof it. In additionthe condensatesystemprovidedthe caDa--bilityof removig gas fromthe liquidgas separatoranddisposingof itas well as provi

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    e The passive thermal system utilized thermal coatings, thermal curtains andinsulationsto cont_'olthe gain and loss of heat both internally andexternally.

    Detailsof these systems are given in Paragraphs 2.4, 2.5, and 2.6.

    1.2.7 Electrical Power SystemThe AM housed eight nickel-cadmium (Ni-Cad)batteries and their charge_ and

    regulators to power the many electrical devices aboard the Skylab. These eightPower Conditioning Groups conditioned power from the Orbital Workshop Solar Arrayevery orbit.

    Power Conditioning Group (PCG) outputs were applied to the various AM EPSbuses by appropriate control switching provided on the STS instrument panel orby ground control via the AM Digital Command System (DCS). Each PCG providedconditioned power to using equipment and recharged the batteries during the day-light period. A comprehensivedescription of the EPS is given in Paragraph 2.7.

    1.2.8 Sequential S_,stemThe Sequential System of the Airlock controlled mission events to establish

    the initial orbital configuration of Skylab. The following events were planned tofollow launch:

    e Payload Shroud jettison. Discone antenna deployment.e Deployment Assembly activation to position the ATM. OWS and ATM solar wing deployment.e Venting operations.e OWS radiator shield jettison.e Attitude control transfer.

    Although the Airlock sequential system functionedas required, an OWS meteoroidshield malfunction prevente_ ,_.o,_,_ticeployment of the OWS solar wings.Sequential System details are in Paragraph 2.8.

    1.2.9 InstrumentationS_,stemThe Airlock InstrumentationSystem sensed, conditioned, multiplexed, and

    enccded vehicle, experiment, and biomedical data for transmission to groundstations in either real-time or recorded delayed time. In addition, it provided

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    data for on-board : splays, and through hardlines, enabled readout during groundcheckout. The system included the following subsystems:

    Sensors Used to convert physical quantities being measured (such astemperature or pressure) into proportional electrical signals and SignalConditione,.s- consistingof interface circuits used to conditionincomDatiblesignals.

    e Regulated Power Converters - Devices used to provide stable excitationvoltages to the instrumentationhardware.

    e PCM Multiplexer/Encoder- System used to provide time sequenced andcoded data for transmissionto the Space_light Tracking and Data Network(STDN).

    Tape Recorder/Reproducer- Devices used to acquire and store between stationdata for subsequent playback to STDN in delayed time.

    A description of these subsystems is provided in Section 2.9.

    1.2.10 CommunicationsSystemThe CommunicationsSystem transmitted and received voice, instrumentation

    data, the television data between: crew members in the Skylab and on EVA; crewmembers and ground tracking stations; Skylab systems and ground tracking stations;and Skylab and the rendezvousing Command/ServiceModule. The CommunicationsSystemconsisted of the following subsystems:

    e Audio System - Used In conjunction with the Apollo Voice CommunicationsSystems to provide communicationsamong the three crewmen and betweenSkylab and the Spaceflight Tracking and Data Network (STDN).

    e Digital Command System (DCS) - A sophisticated,automatic command systelnwhich provided the STDN with real-time command capabilitle: for _he AM,OWS, and MDA. The Digital Command System permitted control of experir,ents,antennas, and cluster system functions.

    e Teleprir_ter- In conjunction with the AM receiver/decoders the teleprinterprovided on-board paper copies of data transmitted by th_ SFDN.

    e Time Reference System (TRS) - Provided time correlation to the Pulse CodeModulation (PCM) Data System, automatic reset of certain DCS comands,automatic control of the redundant DCS receiver/decoders,and timing datato the Earth Resources Experiment Package (EREP) and on-board displays inthe AM and OWS.

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    Telemetry Transmission System - Used in conjunction with the Air_ockAntenna System, the Telemetry System provided RF transmissioncapabilityto the STDN during prelaunch, launch, and orbit for real-time data.delayed time data, delayed time voice, and emergency voice (duringrescue transmission),in both stabilizedand unstabilized vehicleattitudes. This system included four telemetry transmitters, three ofwhich could be operated simultaneouslyduring orbital phases.

    Antenna System - Consisted of a modified Gemini Quadriplexer, twomodified Gemini UHF Stub Antennas, four RF Coaxial Switches, two AntennaBooms, two Discone Antennas and a hellcal VHF Ranging Antenna.

    m RendezvousSystems - Consistingof a VHF Ranging System and four trackinglights, these systems facilitated rendezvousof Command Modules (SL-2,-3, and -4) with the Saturn Workshop (SWS). The Airlock equipmentcomprised a VHF Transceiver Assembly, a Ranginq Tone Transfer Assembly(RTTA), and a VHF Ranqing Antenna.

    Detailed information on the CommunicationsSystem may be found in Paragraph 2.10.

    !o2,!! Caution and Warninq System (C&W)The Caution and Warning System monitored critical Skylab parameters and

    provided the crew with audio/visual alerts to imminent hazards and out-of-specconditions which could lead to hazards. Emergency situations resulted inactivation of a Klaxon horn which could be heard throughout the Skylab vehicle.Caution or warning conditions were brought to the crew's attention through crewearphones and speaker/interco_ panels. Emergency parameters were defined as:

    MDA/STSfire. AM aft compartment fire. OWSforward/experiment/crew compartment fire. Rapid chanqe in vehicle pressure.

    Warning parameters included: Low oxygen partial pressure. Primary and secondary coolant flow failure. AM and ATM regulated power bus out-of-spec.

    '_ e Cluster attitude control failure.e EVA suit coolinq out-of-spec.e AM and CS_ crew alerts.

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    C._:,t_o.-.:rame'_rsconsisted of: Mole sieve overtemperature,high carbon dioxide content, flow failure,

    and s_quencing.e OWS ventilation out-of-spec. RapiO condensate tank pressure change.e Primary and secondary coolant temperature out-of-spec. C&W system bus voltage out-of-spec.e EPS voltages out-of-spec. ATM attitude control system malfunctions. ATM coolant system malfunctions.

    System details may be found in Paragraph 2.11.

    1.2.12 Crew SystemsThe Airlock functioned as a nerve center for monitoring and operating many

    complex vehicle sysL_ms, either autumaticallyor by the crew.A. STS - Primary crew controls for AM systems:

    Electrical Power System.e EnvironmentalControl System (ECS)

    Molecular SieveAtmospheric FansCoolant ControlCondensate System

    IntravehicularActivity (IVA) Control Panel.e Flight Logbook and Records.e Cluster Caution and Warning Monitor System.e 02/N2 Gas DistributionSystem.

    _ B. Lock Compartment - EVA/IVA Operations_ e EVA/IVA Control Panels (2).

    Internal and EVA Lighting Controls., e Compartment Pressure Displays.

    Vacuum Source.C. Aft Compartment

    | OWS Fntry Lighting.e Thermal Fan and Valve Control.

    , M50g Recharge Station.

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    Other AM Crew Systems included the followinq: Mobility Aids. Internal Lighting. Communications- Placement of internal voice communications. Stowage.

    Additional information concerning Crew Systems may be found in Paragraph 2.12.

    1.2.13 TrainersMDAC-E designed, built, maintained, and updated the NASA Trainer (NT), the

    Neutral BuoyancyTrainer (NBT), the Zero-G Trainer and the zero-g aft compart-3nt(part task) trainer. In addition, MDAC-E assisted MSFC in convertinq the AirlockStatic Test Article (STA-3),after completionof full-scale vibro-acoustictestinginto the Skylab Systems Integration Equipment (SSIE) unit. Of lower fidelity thanthe NASA Trainer at JSC, the SSIE was used at MSFC for mission support of crew EVA

    The NBT was used in the MSFC Neutral Buoyance Facility both premission andduring the missiun to support EVA task training. It was used extensively duringthe early days of SL-I missior,to develop the techniques and procedures used by thSL-2 crew to release and deploy SAS Wing #1 and to erect a solar shield. TheNBT was used throughout the mission for this type of real time mission support.

    1.2.14 ExperimentsThe experiments and experiment support equipment which were mounted on the

    Airlock are as follows:e D024 Thermal Control Coatings - Evaluated selected thermal control

    coatings exposed to near-earthspace environment.e S193 Microwave Radiometer Scatterometer/Altimeter- Determined land/sea

    characteristicsfrom active/passive microwave measurements,e $230 MagnetosphericParticle Collection- Measured fluxes and composition

    of precipitatina magnetospheric ions and trapped particles.e Radio Noise Burst Monitor - Permitted prompt detection of solar flare

    activity. M509 Gaseous Nitrogen '"' 'N2} Bottle Recharge Station - Supporting hardware

    for recharging three OWS-stowed N2 bottles.Paragraph 2.14 provides detailed information on AM experiment hardware.

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    1.2.15 GroundSupportEquipment(GSE)AirlockGSE is nonflighthardwareand softwareused in supportof the flight

    articleto satisfya specificsupportfunctionor to accomplisha definedtest.It is used to insp.;ct,est, calibrate,assemble/disassemble,ransport,protect,service,checkout,etc.,or to otherwiseperforma designatedfunctionin supportof the flightarticleduringdevelopmenttesting,manufacturingassembly,acceptancetestinq,systemstesting,delivery,prelaunchcheckout,and launch

    GSE usedin supportof the AM, FAS,DA and PS is categorizedas follows: Handling,Transportationnd MechanicalGSE. Electrical/ElectronicSE. Servicingand FluidsGSE.

    ComprehensiveinformationconcerningAM GSE is given in Paragraph2.15.

    1.2.16 Reliabilityand SafetyThe basicapproachfor achievingAirlockreliabilitygoalsof 0.85 for

    missionsuccessand0.995for crew safetywas to designreliabilityintoallAirlocksystemsand maintainthatreliabilitythroughoutthe fabrication,test,andend use phasesof the program. Majoractivitiesfor achievingthe necessaryAirlockreliabilityincludedthe following:

    FMEA- _ FailureModeand EffectAnalysisidentifiedcriticalmodesofequipmentfailureand facilitatedcorrectiw designchanges.

    m CIL - A CriticalItemList,whichincludedSingleFailurePoints(SFP's)derivedfromthe FMEA,criticalredundant/backupomponents,and launchcriticalcomponents,identifiedprimarycomponentsrequirinqtestemphasis,contingencyprocedures,and managementcontrol.

    ReliabilityModel- Containeda quantitativeassessmentof missionreliabilityand crew safetyfor purposesof recommendingdesignimprovementsto meet AM reliabilitygoals.

    m Tradeand specialstudies,e Design Reviews.e Potential suppliers evaluation.e Reporting system for analysis and nonconformance correction.e NASAAlert investigation and origination of MDAC-EAlerts.

    An MDCReport G671, "Airlock Systems Safety Plan," established the requirements1-17

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    for performing all Airlock functions from design through altitude chamber testingand shipment to KSC without injury te personnel or damage to equipment, AnAirlock Safety Officer verified compliance with the Safety Plan and provideJadditional guidance in areas involving potentially hazar ,us operations notspecifically covered by the plan.

    Sections 3 and 4 provide comprehensive coverage of the Airlock Reliabilityand Safety Programs.

    1.2,17 Testin 9MDAC-Eaccomplished all structur_.l, dynamic, functional and system tests

    necessary for the development, qualification, acceptance and verification of theAirlock Module prelaunch checkout capability, k_fer to Section 5.

    A test plan was implemented for verification tests to define the testdocumentation used tc verify the integrity of the Airlock hardware and toprovide historical test data.

    Development tests were performed to establish a desiqn concept or to provethe feasibility of an established design concept. Development te=ts supplementedthe design process with performance data on equipment and systems, str,mgthcharacteristics of structural elements, and the eCfects of long-ter_ exposure ofmaterials and components to a hard wcuum, as well as to space radiation andcorrosive environments.

    The Airlock Qualification Test Prog.'am was designed to verify the capabilit_of the component hardware to function as specified within the design and perform-ance requirements. This proqram was based on the Apollo Applications TestRequirements (AATR) Document (NHB 8080.3) which required that equipment qualifi-cation testing be varie_ d_pending upon the criticality relationship to the crewsafety and achievement of the mission objectives.

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    Qualification of the Airlock systems was accomp'..ishedith component ieveltesting and equipment er_durancetests. In some instances, components such asthe EnvironmentalControl System/ThermalControl System (ECS/TCS)were combinedinto a module test to verify the system. In this way, endurance testing at thehighest p,_ctisal level verified the equipment performance in mission-si_,ulatedenviron_ents and mission-simulatedduty cycles. Qualificatlon tests verifiedt_at the hardware met the performance/designrequirements to assure operation:isuitabilityof the anticipatede_vironments.

    t.IDAC-Eelivered to HSFC a Structural Test Article (STA-I) which wassubsequentlyrefu;-bishedinto a Dynamic Test Article (STA-3). The structura,testing was performed at the MSFC facilities at Huntsville, Alaba_.aand at theJSC facilities at Houston, Texas by a joint NASA/MDAC/MMC test team. The AirlockDynamic Test Article provided a structurally and dynamically representativevehicle of the Airlock Module. It consisted of a Structural Transition Section,Tunnel and Irusses. The test configurationincluded the Fixed Airlock Shroua,the ATM DeploymentAssembly, the Payload Shroud, and the test article ballasw,_ichsimulated the equipment and experiments in mass, center of gravity andattachmentpoints. The dynamic configuration was representativeof the flightarticle overall weight, center of gravity and mass moments of inertia.

    The objective of thP dynamic test was te subject the dynamic test articieto the predicted flight level acoustic and vibration environments to espErimentallydetermine the frequercy mode shapes and damping values of the Skylab assembly,equipment and subsystems i_ both launch and orbit configurations.

    Section 5.0 provides detailed information on the Airlock Test Philosophy.

    1.2.18 Hission OpeFationsSupportA Skylab CommunicationsCenter was installed at MDAC-E to support MSFC prior

    to and during Skylab launch anf flight operations and to evaluate the Skylabmission performance. In addition, Orbital Assembly flight operations support wasprovided by MDAC-E via the MSFC HuntsvilleOperations Support Center (HOSC).

    : MDAC-E support included analyzing off-nominal Skylab conditions providing additional engineeringdata, and providing systems simulations for systems performance. For additional information,see Section 7.r

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    1.2.19 New Technolo_gsyThe initial Mrlock concept _f a state-of-the-artvehicle had a limited new

    technology requirement. However evolutiun,particularily the wet to dry launchconfigurationchange, required advanced state-of-the-artdesigns, i.e., emergencywarning system, a two-gas spacecraft environment,increasea elo_ctricalpower,active cooling for ATM usage, etc.

    Of the 4Sl New Technology Disclosures submitted, 15 were published as NASATech Briefs and it is anticipated that additional Tech Briefs will be publisheasubsequent to submittal of ti_isreport. Three of the submittals resulted in thepreparation of patent applications by the NASA, and one was filed in the U.S.Patent Office. Additional informationon New Technology is given in Section 8.

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    1.2.20 ConclusionsThe successful Airlock system performar,e during the Skylab Program indicates

    the effect_venesL of the MDAC-E design, fabrication,and test activities thatpreceded the ,iiqhtmission. It also indicates the effectiveness of the missionsupport activity in responding to discrepant conditions and providing real-timework ar_,,ndplans.

    The major conclusion that can be drawn from a program point of view is thatthe Airlock program philosophyof ,naximumuse of existing, qualified spacehardwarewith extensive use of system engineering analysis and previous testresults to identify the minimum supplemental test program required to completesystem verificationwas proven as a valid, economical approach to a successfulmission.

    The most important lesson learned, from its impact on future space systemplanning, is the demonstrated capability of the crewman to function as a majorlink in the system operation. He demonstrated the capability to functioneffectively in zero-g for long periods of time a .d to perform, with proper constraitools, and procedures. Additionally, the ability of the crew to perform contingencEVA's and to accomplish_ifficult repair/maintenanceactivities will be a significainput to all future manned space programs.

    Each s_ction of this report discusses conclusions ar.drecommendationsforthe system or engineering activity being covered.

    Section 9.0 enumerates what MDAC-E considers the .mostsignificant "LessonsLearned" from the Airlock Program and their applicability to future programs.

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    SECTION 2 SYSTEMDESIGNAND PERFORMANCE

    2.1 GENERAL

    2.1.1 Program InceptionThe inception of the MDAC-E Airlock Program dates back to E3 December 1965

    when NASA directed MDAC-E to appraise the appiicability of Gemini hardware forinclusion in an Airlock Module to support use of a spent S-IVB Stage as a mannedshelter and workshop. Subsequently,on 5 April 1966, MDAC-E received a Requestfor Proposal from the NASA to design, develop, manufacture, and check out a SpentStage Experiment Support Module (SSESM) for manned launch aboard a Saturn I-Bvehicle. This module was to provide an interconnectingtunnel _nd airlock betweenthe Apollo Command Module and the S-IVB stage, which would subsequently be convertedinto a manned orbital workshop after its propellant content was expended and it hadbeen purged.

    The SSESM proposal was submitted on II June 1966 and verbal go-ahead wasreceived on 19 August 1966.

    2.1.2 SSESMTh? objectiveof the SSESM was tn demonstrate the economical utilization of an

    S-IVB spent stage hydrogen tank as a workshop for a manned mission. As shown inFigure 2.l-I the SSESM was to be la,mched on a Saturn I-B with an Apollo CSM; itwas to be installed in the Spacecraft Lunar Adapter (SLA) on the Lunar ExplorationModule (LEM) attach points.

    In orbit, the CSM was to separate from the remaining vehicle, rotate 180, anddock using the SSESM docking adapter.

    The SSESM consisted of a tunnel/airlockthat provided a habitable pressurevessel between the spent S-IVB stage and the docked CSM and that supported EVA. Itincluded a section of a Gemini adapter/radiatorand four mounting trusses thatsupported cryogenic 02 and H2 bottles.

    2.1-Ii"_ _.

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    SERVICE APOLLO PANELSCOWMND MODULE

    CURTAIN

    COkWL_ND

    ___ COWAND,_SERVICEMODULEt +PACECRAFT

    SERVICE LEMAOAPTERMODULE

    INSTRUMENTATIONUN224FT S-IVBHYDROGEN

    TANP

    S-IB+ 1; LaunchConfiEurationaturnB9-FIGURE2.1-1 SPENTSTAGEEXPERIMENTUPPORTMODULESSESM)r,

    "'_ 2.1-2

    +" ill +"+_ J-

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    Durin.n,ctivation,a crew member would perform an EVA to renx)veand stow theS-IVb dome nlam:L)leover, connect a flexible tunnel extension to complete thepressuF,_t,lDa_,_,,ew,_;,nd connect tile02 and H2 boom uni_ilicalsto the ServiceM,_dul,;.,_fterp_,,_ingand furbishing, the S-IVG spent stage would have served asa ,qannedlabordtorv. SSESM mission philosophywas that of an open-ended flightoperation _ubseque_itto the first 14 days _ith 30-day goal.

    Over 98:,of the SSESM componentswere Gemini flight qualified hardware and noadditional q_alification testing was to have been per;ormed as long as operatior,lrequirel;w_tltsere similar to Gemini.

    _'.1.3 Wet Workshop EvolutionAs the program matured and requirementswere firmed up, it underwent consider-

    able evolution of mission definition and systems requiren_n;s.Initially, to support additional radiator area and to provide increased

    pressurized volume for expendables and experiment launch stowage, the Geminiadapter was replacedwith a short cylindrical pressure vessel with an axial dockingport and external radiators (Refer to Figure 2.1-2). This version was to belaunched on a Saturn I-B with a CSM for a 30-day mission; it was designated theAirlock Module.

    Subsequently, in December 1966, the pressurized cylindrical o}mpartment waslengthened _nd four radial decking ports were added (the single axial docking portwas retained). Additionally, a solar array system was evaluated for Airlock instal-lation ard gaseous 0,,.nd N2 tanks were designed for installationon the Airlocktrusses (the cryogenic tanks were retained for CSM fuel cell usage). A molecularsieve expe;'imentwas added.

    This configuration (refer to Figure 2.1-2) was to be launched unmanned on aSaturn I-B with tl_ecrew following in a CSM on a second Saturn I-B; crew revisitand station resupply was planned. Additional Saturn I-B launcheswere required toorbit and rendezvous either a Lunar Mapping and Survey Station Module (SM&SS) or aLunar Module/Apollo Telescope Mount (LM/ATM)which was to be docked into one of theradial docking ports by remote control. The orbital configuration is shown inFigure 2.1-3.

    2.1-3

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    j" .... _ ---- SERVICEMODULEENGINEBELL [ ' -1

    / ,'-AXIAL DOCKINGORT/ ,RESSURIZED ICI_IPARI_ENTTUNNEL_$Y!JTRUSSASSY

    /tL S-IVBJl HYDROGEN

    / SATURNB //

    AirlockLaunchConfiguration AirlockLaunchConfiguration(MannedLaunch) (UnmannedLaunch)

    FIGURE2.1-2 WETWORKSHOPONFIGURATIONVOLUTIONROMSPENTSTAGE, EXPERIMENTUPPORTMODULE

    _, 2.1-4

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    co.

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    2.1.4 Wet Workshop ConflgurationBy Mid-1967 a firm workshop configuration had evolved and major changes had

    been made to the Airlock Module and its systems.

    The forward end of the pressurized cylinder, includinn the docking ports, wasrcn_ved as part of the AM and a new module, the Multiple Docking Adapter (MDA)created. The MDAwas to be Governnw_nt Furnished, but the radiators covering theexterior of the MDAremained part of the AM task. The solar arrays were removedfrom the AM and added onto the O&5. Both the cryoqenic 02/H 2 and gaseous 02/N 2supplies were removed from the AM; gases were to be supplied from the CSMthrough.in umbilical. Battery modules were added onto the AM trusses and a scientificairlock was adned to the AM. This configuration as shown in Figures 2.1-4 and2.1-5 was the Apollo Application Program (AAP) "wet" workshop configuration.

    The AAP "wet" workshop mission profile also undm_vent considerable change.In Mid-1967 the mission consisted of two CSM launches, an unmanned orbital workshoplaunch and an unn_nned LM/ATM launch. All launches were on Saturn I-B vehicleswith total mission duration of up to 9 months, as shown in Fig,re 2.1-6. Apossible CSM revisit was considered within 6 to 12 months after AAP-3 splashdown.

    By Mid-1968 the AAP mission hod evolved into a 28-day mission and two 56-daymissions with 90-day orbital storage periods in between; all five launches were bySaturn I-B:

    T.,ree manned CSMlaunches. One unmanned workshop launch. One unmanned LM/AI'M launch.

    2.1.5 Dry Workshop Confi.quration(3n 28 August 1969 the wet workshop configuration was superseded by a dry work-

    shop configuration -- the Skylab. The basic chanqe was to launch the workshop,including all experiments and expendables, in a single unmanned Saturn V launch.

    The S-IVB stage was to be launched dry after having been configured onthe ground for manned laboratory use.

    ' e Separate launch of LM/ATM was eliminated, and the ATMwas included in theunmanned workshop launch payload.

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    LaunchConfigur3tior, ClusterConfiguration(AAP-2) (AAP-3/AAP-4)" //-- MDAt_ S_VB SOLARARRAY

    I _ _ _ AIRLOCK SOLARARRAY_llr4"I- /_ MODULE ---/ \

    S-IVB

    ORBITPLANE-"" / ANTENNA\

    , ,' PANEL-_I _l

    'DIPOLEANTENN,_

    ./_ SATURNB TOWARDUNANTENNA

    (FARSIDE)L_,/A'rM ARRAY

    FIGURE2.1-4 APOLLOAPPLICATIONSROGRAMWETWORKSHOPONFIGURATION2.1-7

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    2.1-8

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    _.=:=zCi_l_'= I 5"'_ I

    '= '_ i,=O=: I..- _" I!1-

    I0._< I-,- M =,a :_ .,,.., __ _- o L_J_ ' _._---. =_ ,,_= I - " =.i I ,= =:

    N u.

    R ,1 _ =$3111NFIlVlS2.1-9

    ,' I

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    The planned mission profile of the Skylab, shown in Figure I-6, included anunmanned workshop launch on a Saturn V vehicle and three successive CSMlaunches onc f,,_.urn I-B vehicles. Manned operation periods of 28_ 56, and 56 days were plannedwith nominal unmanned storage periods of 57 and 37 days. Launch configurations ofboth the unmanned workshop and the manned CSMare shown in Figure I-4.

    The change to the dry workshop involved major chanqes to the Airlock Module. Addition of Deployment Assembly (DA), to deploy the ATM 90 from launch

    to orbital operating position.e Addition of a new design, jettisonable Payload Shroud (PS) to support the

    ATM during launch and to provide aerodynamic a,;dcontaminationprotectionuntil jettisoned in orbit -- the PS replaced the SLA.

    Addition of a Fixed Airlock Shroud (FAS) to provide launch support for theAM/MDA/PS/DA/ATM.

    Additiun of tankage to supply gaseous 02 and N2 for the cluster atmosphericgas system.

    m Addition of two-gas control system.m Deletion of the scientific airlock (moved to OWS).

    Change in MDA docking port configuration (from five to two) and amatching change in AM radiator panels installed on the MDA.

    e Addition of an active cooling system for the ATM control and display panel. Thermal blanket relocationand redesign. Revised AM electrical power system to provide for cluster power load sharing

    with the ATM electrical power system, and deletion of the CSM as a clusterelectrical power source.

    e Provision of a cluster "_ution and warning system.

    The as-flown Airlock Module configuration is shown in Figure I-3 w_th theother modules of the Skylab cluster configuration. Figure 2.1-7, the AirlockModule weight history from SSESMto SL-I launch, indicates, on a weight basis, themagnitude of the Airlock system changes through its design phase -- from 7985 lbsto 75978 Ibs all-up launch weight with the major change associated with theconversion to a dry launch workshop configuration.

    Concurrent with the major mission and vehiL!e changes were many AM systemrequirement changes and hardware redesigns and modifications. Where pertinent to

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    understandinq,system design evolution is discussed in the individualsystpmreport sectio._s.

    Although the Airlock Module evolved from the simple SSESM to a highly complexspace vehicle over the life of the program, the primary design requirement of+_akinemaximum use of existing flight qualified hardware remained. Additionally,the verificationprocess continued to stress extensive use of system engineeringanalysis and previous test results in identifying the supplemental tests necessaryto assure confidencein achieving primary mission objectives and preserving crewsafety.

    L

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    2.2.1 Design R_equirementsThe structures and i_chanical systems were the basic fra_Iwawo_,,on which all

    Airieck systems depended. The requirements nrew through the evolution period,resulting in four elements, the Airlock Module, the Deployment Assembly, FixedAirlock Shroud and the Payload Shroud. (The Payload Shroud is discussed in MDCReport G467qA.)

    2.2.1.1 Airlock Module (AM)The AMwas required to provid_ a pressurized vessel to house cluster controls,

    allow passage between the CSM and the OWS, to permit EVA, and to be a structuralsupport to other cluster elements.

    The AM was confinured, as shown in Figure 2.2-I, with four major elements.A. Structural Transitien Section (STS) and Radiators - The STS was the

    structural transition from the 120-inch diameter MDAto the 65-inchdiameter AM tunnel section. The STS contained four windows for exte_'nalviewing, with movable wi1_dow covers for thermal/meteoroid protection.Radiators were mounted around the periphery of the STS and portions of theMDAto provide thermal/meteoroid protection as well as perform their basicfunction as space radiators. The internal volume of the STS housed equip-ment and controls for the electrical, communication, instrumentation,thermal, environn_ental, and [VA/IVA systems.

    B. Tunnel Assembly - The tunnel assembly was a pressure vessel providing asystem of hatches that functioned as an Airlock to permit EVA. The _zeof the lock compartn_nt with all hatches closed was required to accomn_datetwo pressure suited astronauts with their EVA equipment. All hatchoperations were to be desiqned such that they would bc easily operated bya pressure suited astronaut. The internal volume of the tunnel assemblywas sized to house and support equipment and controls for the electrical,communications, instrun_entation, _nvironmental and crew s',stems.

    C. Flexible Tunnel Extension - The configuration of the Airloc_ Module andthe OWSdictated the need for a pressure-tight passageway between thesetwo nw)dules that would acconmlodate relative deflections with minimum loadtransfer. A redundantly sealed, flexible tunnel was designed to providethis passageway.

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    S $TRUC,LIRETRANSITION.// SECTION/._ TUNNELASSY

    J/-- TRUSSASSY

    i

    FIGURE2.2-I AIRLOCKMODULE

    v

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    D. Support Ir_,ss Assembly - The AM and MDAwere supperted by four truss:,_=,,,,,,:cs_" "",,,:t ,,-'_'e ,_...... to the t,-nne! assemhly and mated :_ith four attachpoints on tne 7AS. The trusses were also used to support N2 tanks,battery n',_Huies, experiments and miscel!aneous equipment.

    2.2.1.2 Deploynw_nt Assembly (DA)A deployment assembly was required for rotation of the ATM from a launch

    stowed position to the mission operating position. The ATM was supported duringground operations and launch by the PS. Upon PS separation the ATM was mechanicallyrigidized to the DA which was then rotated 90 into its in-orbit position, with apointing accuracy of +! "_. Rotation of the ATMwas, to be accomplished in less thanlO minutes. The natural frequency of the deployed ATM/DAwas to be greater thanO.6 Hertz.

    2.2.1.3 Fixed Airlock Shroud (FAS)_, structural assembly was to interface with the IU, provide continuity of

    external surface configuration and provide attachments for the DA, AM, PS, and02 tanks. Concentrated loads generated at these attachments were to be distri-buted by the FAS to the IU interface. Access and ground umbilical doors wererequired in the FAS. The FAS was also used to support ant_.nnas and miscellaneousEVA equipment.

    2.2-3

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    2.2.2 Systems Bescription

    2.2.2.1 Airlock Module (AM)The final configuration of the airlock module extended from the MDAinter-face at Station 200 to the four FAS attach points at Station I00 and the OWS

    done at Station -11.45.

    A. Structure Transition Section (STS) and Radiators - The STS structure,shown in Figure 2.2-2 provided the structural transition from theMultiple Docking Adapter (MDA) to the airlock tunnel. The enclosedvolunw_ of the STS was 288 cu. ft.

    The STS structure was an aluminum welded pressurized cylinder, 47 incheslong and 120 inches in dian_ter, of stressed skin, semi-monocoquecon-struction. At the forward end a machin__dring interfaced with tileMDA.Stringers and 1ongeronswere resistance welded externally to the skinto carry bending and axial loads. Intermediateinternal rings addedsupport. Eight internal intercostalsalong with the truss attachmentfittings transferredSTS shell loads to the support trusses. The STSbulkhead provided the transition from 120-inch dianmter to 65-inch dia-nw_terto mate with the tunnel assembly. Machined rings were utilizedto make a typical flanged, bolted interface. The STS bulkhead alongwith the tunnel shear webs and the aft cctagon ring provided shearcontinuity of tl}eA_ and redistributed loads to the Ah sdpport trusses.Sixteen radial sheet metal channels and eight machined titanium radialfittings, which included lugs for attaching the STS to the trusses,stiffened the STS bu]khead that interfacedwith the AM tunnel. Fourdouble pane glass viewing ports allowed visibility. Each windowwas protected when not in use by an external movable cover assembly,actuated from inside tileSTS by a manual crank. The cover served a dLlalpurpose: to minimize n_teoroid impacts on the glass, and to minimizeheat loss from the cabin area.

    The Airlock Module Radiator panels served as a ,wzteoroidshield for partof the pressure vessel skin in addition to their basic function as spaceradiators. The radiators were mounted on the STS and MDA. To minimize

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    OO ...yAMTUNNELINTERFACE

    SEJIIMONOCOQUECYLINDER

    RADIATORS

    I (4 PLACES)(COVERNOTSHOWN)

    A-.J

    f iVfttOOWSSEMBLYS'-TSINDOWCOVER "_ UMSTR/NG.:R

    MAGNESIUMADIATORKINJ _v "-,GEMINIRADIATORXTRUSIONSECTIONA-A

    FIGURE2.2-2 STSANDRADIATORS2.2-5

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    development and thermal testing, the panels were designed of the samematerials and detail constructionused on the Gen_iniSpacecraft radiator.Existing Gemini bulb-tee shaped magnesium alloy extrusions which provideda flow path for the coolant fluid were seam welded to a magnesium alloyskin. Each radiator panel was supported three inches outside the pres-sure vessel skin by fiberglass laminate angles. The fiberglass laminateangles minimized the heat conduction from the cabin area. Radiatorlocations for the STS are shown in Figure 2.2-2. Welded joints connect-ing most of the radiator coolant tubes minimized possibility of leakage.Mechanical connectors, utilizing Voi-Shanwashers for seals, connectedthe radiator to the coolant loop and joined the radiator panel assemblietogether.

    B. Tunnel Assembl_,- The tunnel assembly was a pressurized seminmnocoquea]uminum cylinder 65 inches in diameter, 153 inches long and was con-figured as shown in Figure 2.2-3. External shear webs, an octagonalbulkhead and the STS bulkhead provided attachment and shear continuitybetween the tunnel assembly and the four truss assemblies. Two internalcircular bulkheads with mating hatches divided the tunnel assembly intothree compartments. Hatch seals and latching mechanisms were providedin these bulkheads. The forward compartment was 31 inches long and interfaced,_,ithhe

    STS section. It provided support for stowage containers, taperecorders, and miscellaneous equipment.

    The center (lock) compartment (volume 170 cuft) was 80 incheslong and included a modifi__dGemini crew hatch for ingress/egressduring EVA.

    The aft compartment was 42 inches long and provided a housing toi support the OWS environmental control system.

    (1) Internal Hatches -.The forward and aft internal hatches illustratedin Figures 2.2-3 at_d2.2-4 were located at AMS 122 and AMS 42,respectively. Tileiroriginal function was to seal off the lockcompartment from the rest of the Skylab during EVA, however, the OWShatch was used ir_conjunctionwith :he AM forward hatch to performthis function during t_'emission, r)othAM hatches were machinings

    _ 49.5 inches in diameter, with stiff,.=nersttached radially. An

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    /

    ,- OCTAGONALINGC)0/

    CLUSTER 'CENTERLINE

    STS //,.,INTERFACE_' "%. ,', j SHEARWEBS- --- TRUSSTOTUNNEL GEMINIHATCH

    ExternalConfigurationViewRotated1800AboutClusterCenterlineo ShowEVAHatch

    - HATCH-OPENOSITION HATCH-OPENOSlTION-_/- HATCH-CLOSEDOSITION._ OWSI Fwo \ 'COMPARTMENT LOCKCOMPARTMENT AFT U_OMPARMENT

    "'_ d

    lAMS_.02Am122._ BUL_r_DS Am42.OO AMS._

    InternalConfigurationFIGURE2.2-3 TUNNELASSEMBLY

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    8.5 inch dia_,ete:"ual pane window in each hatch enabled viewingof the lock from both fonvard and aft comparb_ents.Eaci_hatch was hinged to fold along the tunnel wall and ensurecorrect closing orientdtion. A molded elaston_r hatch seal wasinstalled on each bulkhead.

    Each latching system used a cable which was routed around thecompartnw_ntbulkhead near the periphery of each hatch, drivingnine (Gemini) hatch latch assemblies. Each hatch was latchedwhen the handle was rotated through approximately 145 degrees,with a 25 lb. maximum load applied on the handle. A positive lockwas included in the handle mechanism on the aft hatch.

    VALVEHANDLE _ _ _ \i_i.'_ANDPOSITIVELOCKINGEVICE-_. - HATCH

    ill'iI _'.._'_:""L_ ---I_" _ _Ik\\CLOSEDOSITIONI IOPENPOSITIONI

    ,_ WINDOWLUNGER-.,'_--'_-_ .-_LOCKASSEMBLYPRESSURE..._ " ' " --k ,_'> / "-WINDOW8.5DIA _.,'.",'/.,C_)_'VALVE _" -- _-_ ._ """-. ........-_// HANDLE---_/ ";._,'_-BEARING9LATC'IESGEMINI-_-___ STIFFNER_ ROLLERLEVEL-/VIEWBCREWMATCHYPE _y 9(VIEWKGAFTATFWDHATCH)

    ; FIGURE2.2-4 INTERNALHATCH;_ 2.2 -8

    -,_ ._!,e"?-_- ................ ,

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    _,) [xt,a Vehicular ',ctivitv l;.v_/ Hatch - The EVA hatch (Figure c._-5)was a modified qemini design titanium structure shaped like aconical sectioa, hinged to the AM torque box by means of four lugs.A molded elastomer hatch seal was installed on the sill assembly.A single stroke ha_dle motion through approximately 153 degreesactuated the latching system consisting of a series of gear, linksand twelve latches. This differed from the Gemini hatch in thattile Gemini configuration used a mul ti stroke ratchet-type handlemotion. A double n_ne ,,,indo_., in the hatch enabled viewinq of theaft portion of the EVA quadrant. A tie-down harness was attachedto the EVA hatch window frame to restrain a government-furnishedremovable machined aluminum protective window cover during EVA.

    C. Flexible Tunnel Extension AssemblX - A metallic convolute flexiDie bel_lows 42.5 inches inside diameter by 13.0 inches long formed the pr:ssur-ized passageway between the AM and OWS, a_ shov.n in Figure 2.2-6. Theattachment to the All and OWSwas made with 60 indexed .50 inch diameterholes and .25 inch diameter bolts, centered on a 43.863 inch diameter.The over size holes allowed for alignment tolerances. The matingflanges at the aft AM bulkhead and OWSforward dome interfaces weresealed by a molded elastomer material. All attaching hardware wasselected to maintain clamp-up during periods of AM/OWSthermal expansionand contraction. A fluorocarbon coating applied to the internal surfaceof the bellows provided a redundant pressure seal.

    D. Support Truss Assemblies - The basic truss assembly shown in Figure2.2-7 is typical for all four truss assemblies. Minor modificationswere required on each truss assembly to support miscellaneous equip-ment. The trusses were fusion welded aluminum tubes. Weight savingwas accomplished by selective chemical milling. Machined fittings,fusion welded to the truss tubes, provided attachment to adjoiningstructure. The N2 tanks were mounted on gimbals to isolate them fromtrusc_deflections and resulting loads

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    FLEXIBLETUNNEL

    AMTUNNELASSEMBLY OWSDOME

    FLEXIBLETUNNELEXTENSION" MOLDEDELASTOMER

    MOLDEDLASTOMER SEALSEAL--_

    AMOWSATTAC

    _ AMBULKHEADOWSDOME

    AAMS0,00

    FIGURE2.2-6 FLEXIBLETUNNELEXTENSION

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    b,ASAI'FACHMENT

    CEWITHTUNNELSHEARWEBS

    N2TANK /-- SUPPORT_-- SUPPORT_-.

    / _ _" _NUT FRAMEG'MBAL

    : "- STUD SUPPORTASSEMBLYA-A

    FIGURE2.2-7 SUPPORTRUSSASSEMBLY- 22-12